Panels for Spas

ABSTRACT

Panels are provided that are usable in a skirt surrounding a frame of a spa. The panels can have a multi-tone appearance and can be made from durable, low maintenance synthetic materials.

FIELD

This application relates to panels for spas, and in particular panelsusable with spas having a skirt surrounding a frame supporting a vesselfor containing water.

BACKGROUND

Spas, including hot tubs and jetted bath tubs, often are constructed ofa vessel or shell for containing water and that is supported in a frame.To provide an attractive appearance and hide pumps, jets andinterconnecting piping and the like from view, the frame can include asurrounding decorative skirt. This skirting has been constructed out ofdifferent types of wood arranged, for instance, for a wainscoting-typeor other tongue-and-groove appearance and attached to the frame.

The appearance of the wood skirt, such as the stain, color or type ofwood, could be selected when the spa was originally built. However,changes to the appearance of the skirt were limited. While the skirtcould be repainted or sanded and restrained, those options can be timeconsuming and do not permit convenient changes in the appearance of theskirt, such as to update the skirt to match a new location for the spaor a new decorating scheme of the surrounding environment.

Another disadvantage of wood skirts is the costs and time formanufacturing. To make the wood skirts, the multiple slats of the skirtare often assembled and attached to the frame, and the wood skirtsanded, stained and/or painted. Those steps can be labor-intensive, canrequire special ventilation during the process, as well as add timeneeded for the stain or paint to dry after initial application orbetween coatings when multiple coatings are applied.

Yet another disadvantage of wood skirts is that they can requiremaintenance and can be difficult to repair if damaged. The maintenancecan involve labor-intensive reapplication of stain, sealing orprotecting layers to maintain the visual appearance of the wood skirt.Even when maintained, the environment in which the spa is used candegrade the appearance of the skirt, particularly when used outdoors.For instance, the wood skirt can be exposed to water from the spa, waterfrom yard irrigation systems, direct sunlight, and a wide variation oftemperature changes, in addition to impacts from lawnmowers and lawncare tools, damage during shipping and the like. Those environmentalfactors can also make it difficult for a portion of the wood skirt to bereplaced or repaired, such as if damaged, as the same stains and paintsmay not match the existing, weathered appearance. This can necessitateredoing the entire wood skirt to have a wood skirt of a consistentappearance.

Skirts made of synthetic materials have been used, but often mimic woodin appearance and application. That is, synthetic slats—such as thosejoined in a tongue-and-groove arrangement—can still be labor-intensiveto assemble and attach to the frame. The customization options for thesynthetic skirts can be limited, and replacing an existing skirt toupdate an appearance can also be labor-intensive, as such skirts areoften screwed directly to the frames and/or adhesively attached toadjacent portions of the skirts or the frame. In order to gain access tothe inner workings of the spa disposed behind the skirt, doors wereformed in the skirt or portions of the skirt were unscrewed and removed.Both of these are disadvantageous, the former because it can mar thevisual appearance of the spa and the latter because it can betime-consuming.

SUMMARY

Panels are provided that have improved durability, ease of manufactureand are configured to facilitate enhanced appearances of the spas. Thepanels can be made of synthetic materials that are able to withstand theenvironment in which spas are used without significantly degrading,thereby providing for a longer life span of the panels withoutsubstantial maintenance being required. The panels can be customizedwith different visual graphics, whether shapes, images or the like, byremoving portions of the panels. The removed portions can exposeunderlying portions of the panels, such as with different appearanceproperties, to provide panels that have two or more tones or even seethrough-windows that can be illuminated.

The panels can be incorporated into a panel system that includes a panelthat can be readily removed from the spa. The panel is constrained fromremoval, such as using one or more flanges, but the constraints can beat least partially removed and/or the panel shifted relative to theconstraints to permit the panel to be removed when desired. The flangescan be attached relative to a frame supporting a vessel of the spa, andthe removable panel can be part of a skirt at least partially extendingabout the frame.

In order to install or remove a panel, the panel can be shifted awayfrom one of the flanges so that it is no longer constraining the panel,then the panel can be shifted in a different direction away from anotherof the flanges to permit removal of the panel. The ability to readilyremove a panel and substitute a different panel can permit the spa tohave its visual appearance changed, to permit replacement of a damagedpanel, and can facilitate customized manufacturing of spas in a modularmanner.

In one aspect, the panel is generally free to float within itsconstraints, advantageously permitting the panel to expand and contractwithout necessarily buckling or otherwise deforming. In another aspect,the floating of the panel can be constrained in one or more directions,such as by using hardware attached between the panel and the frame orskirt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a spa having a skirt surrounding a framesupporting a vessel for containing water and showing a plurality ofremovable panels of the skirt;

FIG. 2 is partially exploded perspective view one of the removablepanels of the spa of FIG. 1 showing flanges used for constraining thepanel;

FIG. 3 is a detailed view of area III of FIG. 2 showing a tab and slotconnector mountable between the frame and the removable panel;

FIG. 4 is a section view of the removable panel, frame, vessel andflanges of FIG. 2 taken along line IV-IV and showing an optionallighting device;

FIG. 5 is an exploded perspective view of a multipart panel suitable foruse with the spa of FIG. 1 and having an outward layer with a pluralityof openings through which the inward layer is visible;

FIG. 6 is a section view of a composite panel suitable for use with thespa of FIG. 1 and having a removed portion in an outward layer todisplay an underlying inward layer of the panel;

FIG. 7 is a section view of a panel suitable for use with the spa ofFIG. 1 and having a removed portion filled in with a different material;and

FIG. 8 is a section view of a composite panel suitable for use with thespa of FIG. 1 and having an outward layer with a decorative profile.

DETAILED DESCRIPTION OF THE DRAWINGS

Panels and panel systems are provided that provide improved decorativeappearances, are formed of weatherable, low-maintenance materials,reduced time for manufacture and assembly, and/or are readilysubstituted to change the appearance of the spa. In particular, thepanel system can permit reduced time for assembly to the spa, as well asinterchangeability to permit the decorative appearance of the spa to bechanged. The panel system includes a panel that is part of a skirt ofthe spa. The panel is typically constrained from removal from the spa,but can readily be removed from its constraints to permit replacementwith a different panel, such as to change the appearance of the spa orto replace a damaged panel. The panels, which may or may not be used inconjunction with the panel system, are preferably formed of durablesynthetic materials and have a variety of configurations that providefor improved visual appearances and simplified manufacturing.

Turning first to the panel system, a spa 10 incorporating the system isdepicted in FIGS. 1-4. The spa 10 includes a vessel or shell 12 forcontaining water. It is this vessel 12 that a user of the spa can sit induring use of the spa 10. The vessel 12 has a body 16 including adepressed well that is surrounded by a peripheral lip 14. The vessel 12is supported by a frame 20 that extends around the vessel 12. The frame20 can include vertical supports 24 extending between peripheral,horizontal supports 22 and the flange 14 of the vessel 12. A skirt 30 isattached to and surrounds the frame 20, both to provide a decorativeappearance and to enclose the inner workings of the spa 10, which caninclude pumps, heaters, piping and the like. Part of the skirt 30includes a plurality of removable panels 34. The skirt 30 also includescorner panels 32 that are attached to the frame 20. The removable panel34 is typically constrained relative to the remainder of the skirt 30,but can be readily removed to permit another panel to be substituted orfor access to the inner workings of the spa 10.

In the illustrated example, the panels 34 are constrained using severalflanges adjacent side edges of the panels 34, as shown in the explodedview of FIG. 2. Included are a pair of flanges 36 adjacent lateral sideedges of the panel 34, as well as a bottom flange 38 adjacent the bottomedge of the panel 34. The top edge of the panel 34 is positioned to fitin a recess of the vessel 12 between the lip 14 and the body 16, the lip14 of which functions as a flange. When assembled, the flanges 14, 36and 38 constrain all four edges of the panel 34. While the term “flange”is used, any similar constraining structures can be used that restrictoutward removal of the panel 34 from the spa 10, such as unshapedmembers, brackets or the like. Further, although each flange 36 and 38is depicted as being formed from a single member, a plurality ofdifferent members, such as a plurality of pins, brackets or the like,can also be used to constrain the panel 34. Also, the flanges 36 and 38can be built into other parts of the spa 10, as opposed to beingseparate members. For instance, a groove or flange could be formed inportions of the spa adjacent the panel 34, such as the frame 20 or thecorner skirt portions 32.

As shown in the section view of FIG. 4, the flanges 36 and 38 caninclude a base 45 with an upstanding leg 44 and a depending leg 43. Thedepending leg 43 can be attached to the frame 20 or remainder of theskirt 30. The base 45 can restrict lateral movement of the panel 34, inthe case of the flanges 36 adjacent the lateral side edges of the panel34, or can restrict vertical movement of the panel 34, in the case ofthe flange 38 adjacent the bottom edge of the panel 34. The upstandingleg 44 of the flanges 36 and 38 can restrict movement of the panel 34away from the spa 10. The flanges 36 and 38 can be directly attached tothe frame 20, or can be attached relative to the frame 20 viaintermediate portions of the skirt 30, such as the skirt corner panels32. In particular, the bottom flange 38 can be attached to thehorizontal support 22 of the frame 20, and the side flanges 36 can beattached to either or both of the skirt corner panels 32 and thevertical supports 24 of the frame 20. The flanges 36 and 38 can beattached to the spa 10 using screws or other such fasteners. To thisend, preformed screw holes can be disposed in the flanges 36 and 38 tofacilitate assembly.

The panel 34 preferably, though not necessarily, is generally free tofloat within the confines of the flanges 14, 36 and 38. This floatingcan accommodate expansion and contraction of the panel 34, such asduring temperature changes. This can assist in reducing buckling of thepanel 34. The panel 34 may be constrained to a greater degree in onedirection than another, such as to a greater degree in lateraldirections and opposed to vertical directions. Separate from theconstraining flanges 36, 38 and lip 14, the panel 34 can also beattached relative to the spa 10. For example, hardware may be attachedto the panel 34 that can be joined, hung or secured to hardware attachedrelative to the spa 10. In the illustrated example, the hardware caninclude a tab 40 attached to the back of the panel 34 and a bracket 42attached to the vertical support 24, as illustrated in FIG. 3, or viceversa. The bracket 42 can project outwardly from the vertical support 24to effectively form a slot between a portion of the bracket 42 and thevertical support 24 that is configured to receive the tab 40. When thetab 40 is inserted in the slot bounded by a portion of the bracket 42and the vertical support 24, the panel 34 is essentially hung relativeto the frame 20. That is, the panel 34 is constricted from side-to-sidemovement and downward movement (toward the horizontal supports 22 of theframe 20), but is free to move upwardly. Depending upon the particularconfiguration of the tab 40 and bracket 42, the panel 34 may also beconstrained by the hardware from movement outwardly from the spa 10.Other types of hardware can be used, including hardware that restrictsmovement in all directions.

To assemble the panel 34 to the spa 10, the bottom flange 38 can firstbe attached to the horizontal supports 22. The panel 34 can then beinserted between the lip 14 of the vessel 12 and the bottom flange 38.The distance between a base portion of the lip and the base 45 of thebottom flange 38, and in particular the distance between the upstandingleg 44 and the recess of the lip 14 is such that the panel 34 can clearthe upstanding leg 44 when the upper edge portion is within the lip 14.In one example, the upper edge portion of the panel 34 can be insertedat a slight angle into the recess of the lip 14, which can permit thebottom edge portion of the panel 34 to clear the upstanding leg 44 ofthe bottom flange 38 as the bottom edge portion of the panel 34 ispivoted to a position past the upstanding leg 44 and toward the spa 10.The panel 34 can then be allowed to move downward so that it is restingon the base 45 of the bottom flange 38, while being constrained fromoutward movement by both the upstanding leg 44 of the bottom flange 38and the lip 14 of the vessel 12. If the tab-and-slot fastener is beingused, then the tab 40 can also be slid into the slot formed between thebracket 42 and the vertical support 24 to further constrain the panel34. The side flanges 36 can then optionally be attached to the spa 10 toconstrain the adjacent the side edge portions of the panel 34.

In order to remove the panel 34 from the spa 10, one or both sideflanges 36, if present, can be removed. If only one of the side flanges36 is removed, then the panel 34 can be laterally slide away from theother of the side flanges 36. Once unconstrained by the side flanges 36,the panel 34 can be shifted upwardly toward the lip 14 of the vessel 12to free the bottom edge portion of the panel 34 from constraint by theupstanding leg 44 of the bottom flange 38. Once free, the bottom edgeportion of the panel 34 can be pivoted outwardly while the upper edgeportion remains in the recess of the lip 14. Next, the outwardly-pivotedpanel 34 can be shifted downwardly to free the upper edge portion of thepanel 34 from the lip 14 of the vessel 12. In this manner, the panel 34can be readily removed, and, using the steps described above, replacedwith the same or a different panel 34. Although these steps have beendescribed with inserting or shifting the upper edge portion of the panel34 into the recess of the lip 14 first, the opposite sequence could alsobe utilized for insertion and removal of the panel 34.

The simplified assembly steps for attaching the panel 34 relative to thespa 10 and the modularity of the panels can promote faster assembly ofthe spa 10. Further, a plurality of different panels 34 can be stocked,permitting for customization of the spas 10 during manufacture by usingdifferent panels to provide different visual appearances of the spas 10.Indeed, the sizes of the panels can be standardized for more than onetype of spa 10, further reducing the number of different parts needed toassemble the spa. A reduced number of fasteners can be utilized, as thepanels 34 are not attached at an excess number of locations to the spa10. After assembly of the spa 10, the removable panels 34 permitend-users or installers of the spas 10 to readily substitute panels 34,whether to repair the spa 10 or to change the visual appearance thereof.

The use of the flanges 36 and 38 permits decorative structures to beincorporated into the flanges to enhance the visual appearance andfunctionality of the spa 10. For example, a series of lights 46, such asLEDs, can be optionally inserted into apertures 46 in the base 45 of thebottom flange 38 or into other flanges. The lights can provide anattractive visual appearance to the spa 10, such as by highlighting thepanel 34, and can identify the perimeter of the spa 10.

Turning now to the panels themselves, the panels can be configured toprovide for different visual appearances, while also taking into accountease of manufacturing. In one example, the panel 34 can have decorativeopenings formed therethrough, and a back panel 52 can be attached orpositioned adjacent the rearward side of the panel 34, as illustrated inFIG. 5. The back panel 52 can have a different color and/or texture fromthe panel 34, thereby permitting the different color and/or texture tobe visible through the openings 50 in the panel 34 to effectivelyprovide a two-toned panel. In one example, the back panel 52 can betranslucent. When lighting is positioned behind the back panel 52, theopenings 50 in the panel 34 can be illuminated.

In another example, the panel may be formed to have at least an outerlayer 56 and an inner layer 54, such as using coextrusion techniques.The outer and inner layers 56 and 54 may have different appearanceproperties, such as color, texture, and/or translucency, such that whenthe inner layer 54 is exposed the panel is two-toned. The inner layer 54can be exposed by removing a portion of the outer layer 56, essentiallycreating a window or other opening 58 in the outer layer 56. The outerlayer 56 can be partially removed using CNC-machining, for instance, tocreate geometric shapes or designs, such as those illustrated in FIGS.1, 2 and 5. Furthermore, the panel can have more than two layers withdifferent appearance properties, permitting three or more appearanceproperties in a single panel.

In yet another example, the panel may have a single layer or a primarylayer 60 that is removed, such as using CNC-machining, to form a recess62. The recess 62 can be left open, or the recess can be filled in usingan epoxy or other filler to provide a different appearance property, asdepicted in FIG. 7. In another variation of the panel, the panel canhave one or more layers 66, 68 and 70, as depicted in FIG. 8, with theoutermost layer 68 being a textured skin that can be formed to resemblerocks or stone, by way of example. The three-dimensional appearance ofthe graphics formed in the panels, such as when openings are formed inthe panel or in an outer layer of the panel, or when different depths ofmaterial are removed, can further enhance the decorative aspects of thepanels.

The panels described herein can be made of a variety of syntheticmaterials. Preferably, the materials can withstand the water, chemicaland UV environment that spas 10 are often used in, without significantcolor or other degradation. An example of a suitable material is highdensity polyethylene (HDPE). The flanges 36 and 38 can also be made oflike materials. The panels can be made using extrusion techniques, whichcan advantageously also form the grooves depicted in the panels of FIGS.1-3 and 5. The panels could also be made of an extruded or otherwiseshaped vinyl substrate, which can be primed and coated with an adhesive,then a skin or film material applied (such as using a wrapping machine,including a wrapping machine from RENOLIT AG). The skin or film can haveprotective or decorative properties. Panels having different appearanceproperties can be made using coextrusion techniques. The outer, texturedskin 68 can be formed of acrylonitrile butadiene styrene (ABS), and canbe made using thermoforming techniques and then laminated or otherwiseattached to the other layer or layers of the panel. While the panels aredepicted in the figures as being rectangular, other shapes, such asovular, circular, or multi-sided, can be used with suitablemodifications to the constraining flanges or other constrainingelements.

From the foregoing, it will be appreciated that panels and panelsystems, and methods of manufacture and use, are disclosed herein thatprovide for advantages in terms of assembly, maintenance and visualappearance. However, the disclosure is not limited to the aspects andembodiments described hereinabove, or to any particular embodiments. Forinstance, while described with respect to spas, other types of devicescan also be used, such as bath tubs, showers, or other vessels havingskirts. Also, while specific types of panels are described herein, othertypes of panels can be used with the panel systems.

1. A panel usable as part of a skirt at least partially extending abouta frame supporting a vessel of a spa, the panel comprising: an inwardpart of the panel having a first appearance property; and an outwardpart of the panel having a second appearance property different from thefirst appearance property, a removed portion of the outward part formingan opening in the outward part of the panel exposing an underlyingportion of the inward part of the panel.
 2. The panel of claim 1,wherein the opening is surrounded by the outward part of the panel. 3.The panel of claim 1, wherein the outward part of the panel is disposedon both a front and back side of the inward part of the panel.
 4. Thepanel of claim 1, wherein one of the first and second appearanceproperties is transparency.
 5. The panel of claim 1, wherein one of thefirst and second appearance properties is a color different from theother of the first and second appearance properties such that the panelhas a multi-color appearance.
 6. The panel of claim 1, wherein theinward and outward parts are joined through lamination or coextrusion.7. The panel of claim 1, wherein a portion of the outward part adjacentthe opening is partially removed.
 8. The panel of claim 1, wherein aportion of the inward part coextensive with the opening is partiallyremoved.
 9. The panel of claim 1, wherein an inner part is disposed onan opposite side of the inward part from the outward part, the inwardpart having a removed portion at least partially coextensive with theopening in the outer part to expose the underlying inner part.
 10. Amethod of manufacturing a multi-tone panel usable in a skirt of a spa,the method comprising: coextruding a first material having a firstappearance property and a second material having a second appearanceproperty to form a panel; and removing a portion of the first materialto expose the underlying second material to form a multi-tone panel. 11.The method of claim 10, further including the step of partially removinganother portion of the first material to a depth less than the thicknessof the first material of the panel.
 12. The method of claim 10, whereinthe step of removing the portion of the first material further includesusing a computer-controlled machine to remove the first material in apattern.
 13. A spa comprising: a vessel for containing water; a framesupporting the vessel; a skirt extending at least partially around theframe, the skirt including a panel having one or more openings; and alight source disposed behind the panel to illuminate the opening of thepanel.
 14. The spa of claim 13, wherein the opening in the panel isbacked by a translucent sheet.